Toro Reelmaster 2000-D Page 127 Service Manual Download

Page: 127 / 208

Chapter 5

Electrical System

Table of Contents

ELECTRICAL SCHEMATICS and ELECTRICAL

Reels On Indicator Light . . . . . . . . . . . . . . . . . . . . 13

HARNESS and CONNECTOR DRAWINGS

. . . . .

Reel Engage Switch . . . . . . . . . . . . . . . . . . . . . . . . 13

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . .

High Temperature Shutdown Switch . . . . . . . . . . 15

Starting Problems

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . 16

General Run and Transport Problems

. . . . . . . . . .

Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . 16

Cutting Unit Operating Problems

. . . . . . . . . . . . . .

Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . 17

ELECTRICAL SYSTEM QUICK CHECKS

. . . . . . . .

Standard Control Module . . . . . . . . . . . . . . . . . . . . 18

Battery Test (Open Circuit Test)

. . . . . . . . . . . . . . .

Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . 19

Charging System Test

. . . . . . . . . . . . . . . . . . . . . . .

Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Glow Plug System Test

. . . . . . . . . . . . . . . . . . . . . .

Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 21

Starting System Test

. . . . . . . . . . . . . . . . . . . . . . . .

Cutting Unit Interlock Switch . . . . . . . . . . . . . . . . . 22

Check Operation of Interlock Switches

. . . . . . . . .

Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ADJUSTMENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Neutral Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Parking Brake Switch

. . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 25

COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 11

Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Indicator Lights

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Hour Meter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . 29

Reelmaster 2000–D

Page 5 – 1

Electrical System

Electrical

System

Summary of Contents for Reelmaster 2000-D

Page 1: ...he Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury...

Page 2: ...This page is intentionally blank Reelmaster 2000 D ...

Page 3: ...ce and Repairs 4 40 EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLEDISPLACE MENT PISTON PUMP ROSS TORQMOTOR TM MG MF ME AND MJ SE RIES SERVICE PROCEDURE Chapter 5 Electrical System Electrical Schematics and Electrical Harness and Connector Drawings 5 2 Special Tools 5 3 Troubleshooting 5 4 Electrical System Quick Checks 5 8 Adjustments 5 10 Component Testing 5 11 Service and...

Page 4: ...This page is intentionally blank Reelmaster 2000 D ...

Page 5: ... 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 JACKING INSTRUCTIONS 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 4 While Operating 2 Maintenance and Service 3 Safety Reelmaster 2000 D Page 1 1 Safety ...

Page 6: ...UTRAL and cutting units are DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spi...

Page 7: ...t Clean protective screen on machine frequently 10 If engine must be running to perform maintenance or an adjustment keep hands feet clothing and other parts of the body away from cutting units and other mov ing parts Keep bystanders away 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 12 Shut engine off before checking or adding...

Page 8: ...under the frame just to the in side of the front tire 3 Jack front of machine off the ground 4 Position jack stands or hardwood blocks under the frame as close to the wheel as possible to support the machine Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting units of the Reelmaster 2000 D If any decal becomes illegible or damaged i...

Page 9: ...s Manual and Parts Catalog for your Re elmaster at the end of this chapter Refer to Operator s Manual for recommended maintenance intervals Addi tionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your Reelmaster at the end of this section Maintenance Maintenance procedures and recommended service in tervals for your Reelm...

Page 10: ...Rev A 0 09375 Reelmaster 2000 D Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 11: ...er s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fas...

Page 12: ...47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF ...

Page 13: ...5 ft lb 92 9 ft lb 229 22 ft lb 450 37 ft lb 885 80 N cm 1500 150 N cm 36 3 N m 72 7 N m 125 12 N m 310 30 N m 610 50 N m NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above are by 25 for lubricated fasteners Lubricated fasteners based on 75 of the minimum proof load specified in are defined as threads coated with a lubricant such as SAE J1199 The tolera...

Page 14: ...crews Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Thread Size Size Threads per Inch Baseline Torque Baseline Torque Type A Type B No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7...

Page 15: ...maintenance tervals for the Reelmaster 2000 D are covered in the Refer to the Engine Operator s Manual for additional en Traction Unit Operator s Manual Refer to that publica gine specific maintenance procedures Product Records and Maintenance Reelmaster 2000 D Page 2 7 Product Records and Maintenance ...

Page 16: ...________ ________________________________ Date ________________ A B and C Service Required See Operator s Manual for Specifications and Procedures Drain and Flush Fuel Tank Drain and Flush Hydraulic Tank REELMASTER R Unit Designation Hours __________________ __________________ Service to perform circle A B C D Other Remarks B Service every 100 hours C Service every 200 hours D Service every 400 ho...

Page 17: ... 4 Adding Oil to Engine 4 ADJUSTMENTS 5 Adjust Throttle Control 5 Adjust Engine Speed 5 SERVICE AND REPAIRS 6 Fuel System 6 Air Cleaner 8 Exhaust System 10 Radiator 12 Engine Removal 14 Engine Installation 17 Engine PTO 19 BRIGGS STRATTON DAIHATSU ENGINE REPAIR MANUAL Engine Reelmaster 2000 D Page 3 1 Engine ...

Page 18: ...ribed in the Special Tools section The use of some specialized test equipment is explained How ever the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs Stratton Daihatsu diesel engines are supplied through your local Toro Dis tributor If no parts list is available be sure to pro...

Page 19: ...specification Fuel Injection Pump VE Bosch type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity liter U S gal 25 6 5 Governor Mechanical Idle Speed no load 1540 50 RPM High Idle no load 3200 50 RPM Engine Oil SAE 10W30 API CF or better Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal type Cooling System Capaci...

Page 20: ... 1 1 Fuel shutoff valve under the fuel tank Adding Oil to Engine When adding oil to the engine maintain clearance be tween the oil fill device and the oil fill opening in the valve cover Fig 2 This clearance is necessary to allow vent ing when adding engine oil which will prevent oil from running into the breather tube and intake system Figure 2 Engine Page 3 4 Reelmaster 2000 D ...

Page 21: ... or adjusting engine speed Park machine on a level surface lower cutting units and engage parking brake 2 With engine running move remote throttle control le ver to FAST position 3 Using a tachometer check that engine is operating at 3200 50 RPM 4 If high idle speed is incorrect adjust high speed screw on fuel injection pump Fig 4 A Loosen lock nut on high speed screw B Adjust high speed screw to ...

Page 22: ... Fuel hose to injector pump 6 Fuel shut off 7 Hose clamp 8 Fuel hose 9 Return fuel hose from injector pump 10 Tank mount grommet 11 Washer 12 Cap screw 13 Fuel fitting 14 Fuel filter water separator 15 Fuel fitting 2 1 3 9 7 8 7 6 3 4 12 11 10 5 3 15 13 3 4 14 FRONT RIGHT 30 to 60 in lb 3 4 to 6 8 N m Thread locking Compound ...

Page 23: ...Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an ex tended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of contaminates and debris Fuel Tank Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition swit...

Page 24: ... Air cleaner body 2 3 1 6 4 8 7 5 9 FRONT RIGHT 6 ÇÇ ÇÇ 13 10 11 12 14 Removal 1 Remove air cleaner components as needed using Figure 7 as a guide Installation IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figure 7 as a gui...

Page 25: ...Engine This page is intentionally blank Reelmaster 2000 D Page 3 9 Engine ...

Page 26: ...ler 2 Exhaust gasket 3 Muffler header 4 Tailpipe 5 Rubber hanger 6 Rubber isolator 7 Clamp 8 Coupler spring 9 Flange nut 10 Lock nut 11 Flat washer 12 Spacer 13 Cap screw 14 Carriage screw 9 6 9 1 7 4 5 8 3 2 10 11 10 11 12 14 11 13 12 FRONT RIGHT 200 in lb 22 6 N m ...

Page 27: ...ve exhaust gasket Replace gasket if dam aged or torn NOTE Make sure exhaust manifold and muffler head er sealing surfaces are free of debris or damage that may prevent a tight seal 1 If muffler header was removed place exhaust gas ket on the exhaust manifold Secure muffler header to the manifold with four lock washers and hex nuts IMPORTANT Finger tighten all fasteners before securing so there is ...

Page 28: ...ator shield 16 Screw 17 Hose clamp 18 Flange nut 19 Carriage screw 20 Front radiator bracket 21 Radiator 22 Bottom radiator shroud 23 Flange head screw 24 Flange nut 25 Radiator cap decal 26 Warning decal 27 Radiator hose 28 Bulb seal 29 Top radiator hose 30 Radiator tube 31 Flange head screw 32 Flat washer 33 Radiator hose 34 Oil cooler 35 Knob 36 Lock nut 37 Oil cooler bracket 9 5 31 26 33 30 2 ...

Page 29: ...ening mounting fasteners 7 Remove two carriage screws and flange nuts secur ing the front radiator bracket to the frame Remove four cap screws and flange nuts securing the rear radiator bracket to the frame 8 Carefully pull radiator assembly from the machine Plug radiator and hose openings to prevent contamina tion 9 As required remove brackets and shrouds from ra diator using Figure 9 as a guide ...

Page 30: ...ad screws and left fender bracket from the frame 5 Remove cotter pin from brake rod Disconnect brake rod from brake lever Fig 11 6 Remove cap screws and flange nut securing the left footrest to the frame Fig 10 Remove the left foot rest from the machine 7 Drain and remove radiator see Radiator removal 8 Drain and remove hydraulic reservoir see Hydraulic Reservoir in Service and Repair section of C...

Page 31: ...njector pump D Unplug connector with gray wire from the oil pres sure switch located near the engine oil dipstick E Remove connector with red wire from the glow plugs located on the rear side of the cylinder head F Unplug connector with white wire from the engine starter motor located below the exhaust manifold Remove fusible link connector and positive battery cable from the starter motor Fig 13 ...

Page 32: ...9 FRONT RIGHT Lift Tab Lift Tab 20 22 16 Remove engine from machine Fig 15 A Attach short section of chain between lift tabs lo cated on each end of the cylinder head B Connect a hoist or chain fall at the center of the short section of chain Apply enough tension on the short chain so that the engine will be supported as the engine mount brackets are removed C Remove cap screws snubbing washers an...

Page 33: ...PORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while removing the engine C Reinstall engine to the machine Make sure fas tener holes of the engine frames and channel are aligned with the holes in the engine mounts D Secure engine with frames and channel to the engine mounts with cap screws snubbing washers and lock nuts 5 Reconnect electrica...

Page 34: ...ation 14 Add coolant to radiator see Traction Unit Operator s Manual 15 Open fuel shut off valve under the fuel tank 16 Fill hydraulic reservoir with hydraulic fluid see Trac tion Unit Operator s Manual Check reservoir for leaks 17 Slide the left foot rest onto the brake rod Reinstall cap screws and flange nut securing the left footrest to the frame Tighten cap screws Fig 10 18 Connect brake rod t...

Page 35: ...ly 1 Position stub shaft to engine flywheel and install cap screws and flat washers Torque cap screws from 17 to 21 ft lb 23 to 29 N m 2 Install three cap screws and lock washers through non threaded holes in bushing Position bushing to pulley to allow cap screws to thread into pulley Leave cap screws loose 3 Place key into stub shaft slot Slide bushing and pulley assembly onto stub shaft while al...

Page 36: ...This page is intentionally blank Engine Page 3 20 Reelmaster 2000 D ...

Page 37: ...RVICE AND REPAIRS 40 General Precautions for Removing and Installing Hydraulic System Components 40 Check Hydraulic Lines and Hoses 40 Flush Hydraulic System 41 Hydraulic System Start up 42 Hydraulic Pump Drive Belt 43 Traction Charge Pump 44 Traction Charge Pump Service 48 Reel Gear Pump 49 Reel Gear Pump Service Barnes 50 Reel Gear Pump Service Casappa 51 1 Wheel Motor 52 Wheel Motor Service 54 ...

Page 38: ...5 PSI 31 1 to 36 2 bar Lift Control Valve Spool type directional control valve Reel Motor Gear Pump Positive displacement gear type pump Maximum Operating Pressure 4000 PSI 276 bar Hydraulic Manifold Relief Valve Differential area relief valve Cutting Circuit Relief Pressure 2700 to 3300 PSI 186 3 to 227 7 bar Reel Motor Gear motor Maximum Operating Pressure 2250 PSI 155 bar Cross over Relief Pres...

Page 39: ...This page is intentionally blank Hydraulic System Reelmaster 2000 D Page 4 3 Hydraulic System ...

Page 40: ...il 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has Before disconnecting or performing any work tachment ...

Page 41: ...ays replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure O Ring Lock Nut Back up Washer the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight Figure 4 until the washer contacts the face of the ...

Page 42: ...ned 90o for towing See Traction Unit Operator s Manual for Towing Procedures 1 Figure 6 1 By pass valve location Check Hydraulic Fluid The Reelmaster 2000 D hydraulic system is designed to operate on anti wear hydraulic fluid The reservoir holds about 3 3 gallons 12 5 liters of hydraulic fluid Check level of hydraulic fluid daily See Traction Unit Operator s Manual for fluid level checking procedu...

Page 43: ...aster 2000 D Hydraulic System Page 4 7 Hydraulic Schematic Hydraulic Schematic Reelmaster 2000 D All solenoids are shown as de energized Optional 3 Wheel Drive Kit BY PASS VALVE SHUTTLE VLV Hydraulic System ...

Page 44: ...er 2000 D Hydraulic System Page 4 8 Hydraulic Flow Diagrams Optional 3 Wheel Drive Kit BY PASS VALVE Working Pressure Low Pressure Charge Return or Suction Flow Traction Circuit Forward Shown Reelmaster 2000 D ...

Page 45: ... check valves This fil tered oil replaces oil losses from flow through the shuttle valve and small amounts of pump and motor leakage The charge pump and shuttle valve circuits allow for in direct cooling and filtering of the traction circuit If the optional 3 Wheel Drive Kit has been installed the 3WD selector valve allows forward flow to the rear wheel only when the Reel Engagement switch is in t...

Page 46: ...Reelmaster 2000 D Hydraulic System Page 4 10 Optional 3 Wheel Drive Kit BY PASS VALVE Working Pressure Low Pressure Charge Return or Suction Flow Lift Circuit Raise Reelmaster 2000 D ...

Page 47: ...o the lower and outer portions of the lift cylinders Hydraulic pressure against the cylinder pistons pushes the shafts out At the same time the pis tons push the hydraulic fluid in the upper and inner por tions of the lift cylinders out and through the control valve to the piston pump suction When the control valve lever is released spring action returns the spool to the center position and by pas...

Page 48: ...Reelmaster 2000 D Hydraulic System Page 4 12 Optional 3 Wheel Drive Kit BY PASS VALVE Working Pressure Low Pressure Charge Return or Suction Flow Mow Circuit Cutting Units Engaged Reelmaster 2000 D ...

Page 49: ...peed control valve Flow across the speed control valve is pressure compensated by the logic cartridge valve LC1 Any ex cess flow above what the speed control valve is set for is bypassed to the reservoir through the logic cartridge valve With the backlap valve MD1 in the MOW posi tion oil flows through the valve and reel motors which are connected in series Oil flows through the right cen ter and ...

Page 50: ...fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSUREGAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve c...

Page 51: ...ainer for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 13 provides gallons per minute GPM conversion for hydraulic motor case drain leak age measured in either m...

Page 52: ...ossible Cause Hydraulic oil leaks Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Foaming hydraulic fluid Oil level in reservoir is low Hydraulic system has wrong kind of oil One of the pump suction lines has an air leak Hydraulic system operates hot Traction system pressure is high due to load or brakes applied Oil level in reservoir is low or inlet filte...

Page 53: ...tting is wrong for reverse Noisy reel motor drive pump cavita tion Reservoir oil level is low Suction line is restricted Suction line has an air leak Reels will not turn Cross over relief valve s are stuck open the other reels will still rotate Valve S1 is stuck open An electrical problem exists See Chapter 5 Electrical System Relief valve R1 is stuck open LC1 logic valve is stuck open Reel motor ...

Page 54: ... damaged Lift valve control linkage is binding or broken Lift cylinder bushings are binding Reservoir oil level is low Inlet filter is loose or clogged Charge pump pressure or flow is insufficient Implement relief valve is stuck open Lift control valve is damaged Lift cylinders leak internally Cutting units raise but will not stay up Lift cylinders leak internally Lift valve leaks ...

Page 55: ... such an injury 1 Thoroughly clean the machine before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic equipment Contamination will cause exces sive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating c...

Page 56: ...r Suction Flow REVERSE CHARGE RELIEF TOP BOTTOM WHEEL MOTOR FORWARD WHEEL MOTOR FORWARD BOTTOM TOP TO REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM LIFT CONTROL VALVE TO LIFT CONTROL VALVE FROM RESERVOIR TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 Working Pressure TEST GAUGE FORWARD TEST GAUGE Figure 14 Hydraulic System Page 4 20 Reelmaster 2000 D ...

Page 57: ...d 16 Make sure gauge hose is long enough so the operator can read gauge while driving the machine 6 Start engine and move throttle to full speed 3200 50 RPM 7 Drive machine in the forward direction Observe test gauge A Pressure while transporting the machine over a flat level surface should be about 500 PSI B Pressure while mowing should range between 1000 to 2000 PSI and will vary with terrain 8 ...

Page 58: ...LH R1 S1 LC1 MD1 G1 P1 M2 D1 M1 M5 D3 M6 M4 D2 M3 T2 COOLER FC1 FROM LEFT HYDRAULIC MANIFOLD GEAR PUMP Low Pressure Charge Return or Suction Flow TEST GAUGE FILTER TO CHARGE PUMP WHEEL MOTOR TO TRACTION PUMP Working Pressure Figure 17 Hydraulic System Page 4 22 Reelmaster 2000 D ...

Page 59: ...ator can read gauge while driving the machine 2 1 5 Make sure backlap knob on the hydraulic manifold is Figure 18 in the mow position Adjust reel speed knob for typical 1 Hydraulic manifold 2 Test port mowing conditions CAUTION sonal injury from the rotating reel blades Keep away from reels during test to prevent per 6 Start engine and move throttle to full speed 3200 50 RPM Engage the cutting uni...

Page 60: ...essure Charge Return or Suction Flow CHARGE RELIEF TESTER TOP BOTTOM WHEEL MOTOR FORWARD WHEEL MOTOR FORWARD BOTTOM TOP TO REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM LIFT CONTROL VALVE TO LIFT CONTROL VALVE FROM RESERVOIR TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 Working Pressure Figure 19 Hydraulic System Page 4 24 Reelmaster 2000 D ...

Page 61: ...he motor through the tester and into the hose 11 Install flow tester with pressure gauges in series with the motor and the disconnected hose Make sure flow control valve is fully open 12 One person should sit on the seat and operate the machine while another person reads the tester Start en gine 13 Adjust engine speed so pump speed is 2400 RPM engine speed approximately 2700 RPM Verify pump speed ...

Page 62: ... GEAR PUMP COOLER RETURN FROM MANIFOLD FRONT DISCHARGE Low Pressure Charge Return or Suction Flow CHARGE RELIEF TESTER TOP BOTTOM CONTROL VALVE VALVE TOP BOTTOM FILTER OUT REAR BOTTOM LIFT RELIEF MOTOR TO LIFT CYLINDER FROM LIFT CYLINDER TO WHEEL MOTORS TO MANIFOLD TOP TO WHEEL MOTORS REEL LIFT Working Pressure Figure 21 Hydraulic System Page 4 26 Reelmaster 2000 D ...

Page 63: ...ng the lift lever in the raised position watch the pressure gauge Record pressure when the relief valve opens 6 Return lift lever to neutral position Shut off engine 7 Subtract the relief valve closed pressure from the re lief valve open pressure see example below The dif ference should be from 450 to 500 PSI A If this specification is not met adjust lift relief valve B If this specification is me...

Page 64: ...URN FROM MANIFOLD Low Pressure Charge Return or Suction Flow CHARGE RELIEF TOP BOTTOM CONTROL VALVE VALVE TOP BOTTOM FILTER OUT REAR BOTTOM LIFT RELIEF MOTOR T CONNECTION AND GAUGE TO LIFT CYLINDER FROM LIFT CYLINDER TO WHEEL MOTORS TO MANIFOLD TO WHEEL MOTORS TOP REEL LIFT Working Pressure Figure 22 Hydraulic System Page 4 28 Reelmaster 2000 D ...

Page 65: ...edal and lift valve are in neu tral and the parking brake is engaged 6 Operate engine at full speed 3200 50 RPM 7 Pressure gauge should read from 100 to 150 PSI If specification is not met inspect charge relief valve in traction pump 8 A dynamic charge pressure test can be performed as follows A With T connector and pressure gauge still con nected sit in the operator seat and press the traction pe...

Page 66: ...OIR RH CTR LH R1 S1 LC1 MD1 G1 P1 M2 D1 M1 M5 D3 M6 M4 D2 M3 T2 COOLER FC1 FROM LEFT HYDRAULIC MANIFOLD GEAR PUMP Low Pressure Charge Return or Suction Flow TESTER FILTER TO CHARGE PUMP WHEEL MOTOR TO TRACTION PUMP Working Pressure Figure 24 Hydraulic System Page 4 30 Reelmaster 2000 D ...

Page 67: ...and the disconnected hose leading to port P1 of the hydraulic manifold Make sure the flow control valve on the tester is fully open 6 Make sure backlap knob on the valve block is in the mow position 7 Start engine and move throttle to full speed 3200 50 RPM Do not engage the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve until 1500 PSI is obtained Verify...

Page 68: ...M5 D3 M6 M4 D2 M3 HYDRAULIC MANIFOLD FROM REEL DRIVE PUMP TESTER Install tester in series between fitting and hose at the motor right hand motor shown Low Pressure Charge Return or Suction Flow TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR Working Pressure Figure 27 Hydraulic System Page 4 32 Reelmaster 2000 D ...

Page 69: ...ge the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve until the manifold relief opens 9 System pressure should be from 2700 to 3300 PSI as the relief valve opens A If specification is not met adjust relief valve step 10 B If this specification is met go to step 11 NOTE Do not remove relief valve from the hydraulic manifold for adjustment 10 Adjust the re...

Page 70: ...low TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR TEST GAUGE LOCATION T CONNECTION AND GAUGE LOCATION Working Pressure Figure 29 NOTE One way to find a possibly bad reel motor is to have another person observe the machine while mow ing in dense turf A bad motor will run slower produce fewer clippings and may cause marcelling or a wash board appearance on the turf Hydraulic System Page 4 34 ...

Page 71: ...y are expected to be a problem After testing cross over reliefs in the backlap direction make sure the reel motor couplings are torqued see Hy draulic Reel Motor in the Service and Repair section of Chapter 7 Cutting Units 10 If cross over relief pressure is to be tested in the backlap direction clean left hand reel motor and its hose connection leading to manifold port M3 Discon nect hose connect...

Page 72: ...5 D3 M6 M4 D2 M3 Low Pressure Charge Return or Suction Flow HYDRAULIC MANIFOLD FROM REEL GEAR PUMP TESTER MEASURE RH CASE DRAIN FLOW HERE TEST CONNECTION FOR Working Pressure TO COOLER MOTOR FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR R H REEL MOTOR SHOWN Figure 30 Hydraulic System Page 4 36 Reelmaster 2000 D ...

Page 73: ...with the motor and the disconnected return hose Make sure the flow control valve on the tester is fully open 6 Make sure backlap knob on the valve block is in the mow position 7 Clean hose fitting and disconnect case drain hose from the manifold block see table Plug the manifold port CAUTION sonal injury from the rotating reel blades Keep away from reels during test to prevent per 8 One person sho...

Page 74: ...ONTROL VALVE FROM RESERVOIR TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 Working Pressure R H WHEEL MOTOR SHOWN REELS DISENGAGED TO PREVENT FLOW TO REAR WHEEL Figure 31 NOTE Over a period of time a wheel motor can wear internally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load condit...

Page 75: ...d will be trying to move the 12 Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge 13 Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor 14 If specifications are not met the tested wheel motor needs to be repaired or replaced as necessary 15 If remaining front wheel motor require...

Page 76: ...the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components...

Page 77: ...H for this step if you are changing to this type of fluid Use only hydraulic fluids specified in Traction Unit Oper ator s Manual Other fluids could cause system dam age 5 Fill hydraulic reservoir 6 Disconnect electrical connector to the fuel stop sole noid to prevent engine from starting 7 Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pump Repeat this step...

Page 78: ...tart en gage starter for fifteen 15 seconds to prime pump 7 Attach electrical connector to the fuel stop solenoid 8 Make sure traction pedal is in neutral and the cutting unit switch is off Start engine and run it at low idle The charge pump should pick up oil and fill the hydraulic sys tem If there is no indication of fill in 30 seconds stop the engine and determine the cause CAUTION Be careful w...

Page 79: ...Loosen lock nut 13 and cap screw 11 that secure lower end of pump support 3 Loosen lower jam nut and lock nut that secure adjust ing bolt to front engine frame 4 Pivot pump support to allow drive belt to be removed from pulleys Drive Belt Installation 1 Pivot pump support and install drive belt to pulleys 2 Tighten lock nut on adjusting bolt to tension drive belt A used drive belt should deflect 0...

Page 80: ...ting 23 Return hydraulic hose 24 Hydraulic fitting 25 Hose clamp 26 Cap screw 27 Hardened washer 28 Adjusting bolt full thread 29 Jam nut 30 Hydraulic hose 31 Cap screw 32 Protective sleeve 33 Cap screw 34 Top spherical washer 35 Bottom spherical washer 36 Socket head set screw 37 O ring 38 O ring 39 O ring 40 O ring 41 O ring 42 Suction hose 43 Hydraulic hose 44 Suction hose 45 Front engine frame...

Page 81: ...4 7 11 12 22 8 14 21 9 13 3 15 2 1 10 24 16 23 18 17 19 20 25 25 27 26 28 Removal Fig 35 1 Park the machine on a level surface engage parking brake lower cutting units and stop engine Remove key from the ignition switch CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Install plug into the hydraulic reservoir to prevent draining t...

Page 82: ...e pump from the piston pump see Reel Drive Pump Removal 9 Remove hydraulic fittings and O rings from the pumps as required 10 If necessary loosen socket head set screw in taper lock bushing and remove bushing from the piston pump shaft Locate and remove key from piston pump shaft Piston Pump Installation Fig 35 1 Make sure the inside of the taper lock bushing is clean Apply anti seize lubricant to...

Page 83: ...ley to bushing with cap screws and lock washers Torque cap screws from 90 to 120 in lb 10 2 to 13 6 N m in a circular pattern C Verify alignment across engine and pump pulley faces with a straight edge The gap between both faces must not exceed 0 030 0 8 mm 9 Install drive belt to the pulleys see Hydraulic Pump Drive Belt 10 Check traction drive for neutral and neutral switch adjustment see Tracti...

Page 84: ... 20 Check valve 21 Valve plate 22 Bearing cone 23 Cover plate 24 Cover plate 25 Washer 26 Dowel pin 27 Cap screw 28 Cap screw 29 Key 30 Key 31 O ring 32 Shim kit 33 Bearing cup 34 Geroter and coupler assembly 35 O ring 36 Charge pump adapter Figure 37 21 12 4 13 30 22 5 14 17 23 16 32 33 31 19 8 10 9 10 8 6 11 7 29 1 15 3 31 33 24 14 17 22 26 20 20 18 34 35 36 25 27 2 28 NOTE For repair of the tra...

Page 85: ...ove caps or plugs that were put on any hydraulic lines or fittings during disassembly 3 Replace all O rings with new ones Apply clean hy draulic oil to all O rings 4 Place O ring 11 on reel gear pump 5 Position reel gear pump to traction pump the inlet port on the reel gear pump should be facing up Align splines on reel gear pump shaft with traction pump shaft 6 Secure reel gear pump to traction p...

Page 86: ...d or reinstalled 2 Matchmark the inlet side of the gear housing 10 with the mounting flange 3 and the end cover 8 for proper orientation of these three parts during reassemb ly 3 Position the pump with the drive end facing down 4 Remove the four bolts Lift off the end cover and two dowel pins 5 Remove the gear housing ensuring the rear bearing block 13 front bearing block 14 drive gear 11 and idle...

Page 87: ...re that the back side of the mounting flange is free of any contami nation 2 Place the front bearing block with its seal side down onto the mounting flange The open side of the E seal should point toward the matchmark on the inlet side of the mounting flange 3 Apply a light coating of hydraulic oil to the exposed face of the front bearing block Make sure the tape is on the shaft end of the drive g...

Page 88: ...t be replaced as a complete assembly Individual gears body and wear plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only 1 Plug pump ports and clean the outside of the pump thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the front flange and body for assembly purposes Fig ...

Page 89: ...de up IMPORTANT Make sure to not damage the front flange counter bore when removing the seal from the front flange 9 Carefully remove retaining ring and shaft seal from the front flange Discard seal 10 Clean all parts Check all components for burrs scoring nicks and other damage 11 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 39 1 1 Lubricate O ring pressu...

Page 90: ...om the wheel motor Front Wheel Motor Installation Fig 40 1 Place and support wheel motor into the support frame Insert four socket head screws through the sup port frame and wheel motor 2 Slide spacers grass shield and brake bracket onto the cap screws and wheel motor Tighten lock nuts onto cap screws 3 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 4 Inst...

Page 91: ... wheel motor from the rear wheel fork 6 Remove hydraulic fittings and O rings from the wheel motor 3WD Rear Wheel Motor Installation Fig 41 If the optional 3 Wheel Drive Kit has been installed rear wheel motor installation procedure is as follows 1 Place and support wheel motor into the rear wheel fork Insert four socket head screws through the rear wheel fork and wheel motor 2 Tighten lock nuts o...

Page 92: ... washer 29 Thrust bearing Figure 42 5 15 11 2 3 4 10 20 26 27 28 29 1 25 24 23 22 21 19 8 7 6 5 14 13 12 16 17 18 28 10 8 9 LEFT WHEEL MOTOR SHOWN NOTE The wheel motor shown in Figure 42 is the left motor The two wheel motors are identical in construc tion except for end cover differences The end cover of the right motor lacks the shuttle valve and plugs of the left motor shown On machines equippe...

Page 93: ...nd O rings from reel mo tor Discard O rings Installation Fig 43 1 Position key and place coupling on reel motor shaft 2 Install flange nut and torque nut 35 ft lb 47 N m 3 Make sure hydraulic fitting ports and O ring sealing surfaces on the reel motor are clean 4 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 5 Apply clean hydraulic oil to all O rings 6 In...

Page 94: ...s a different back plate than the front motors Service for front and rear reel motors is identi cal Disassembly Fig 44 1 Make sure key is removed from the drive gear shaft 2 Matchmark frontplate body and backplate to assure proper reassembly 3 Secure the motor in a vise with the drive shaft up 4 Remove all eight screws 5 Remove the motor from the vise Remove the front plate from the body A wooden ...

Page 95: ...ace if any scoring exists to a depth of 0 0015 in 0 038 mm 12 Replace body 12 if the inside diameter of the gear pockets exceeds 1 713 in 43 5 mm 13 Make sure that both relief valve plugs are secure if they or the backplate are not being replaced Reassembly Fig 44 1 If replacing the relief valve assembly 19 install ball spring shim O ring and plug into the backplate Hand tighten plug and then torq...

Page 96: ...screw 4 used Figure 44 1 2 3 6 9 9 10 11 13 1 5 7 12 14 15 16 17 18 4 6 7 8 14 33 ft lb 45 N m Disassembly Fig 44 1 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the front flange and body for assembly purposes Fig 44 2 IMPORTANT Prevent damage when clamping the reel motor...

Page 97: ...ts with emery cloth CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 44 4 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement ...

Page 98: ...mo tor Carefully install shaft into front flange 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the front wear plate Apply a light coating of clean hydraulic oil to gear faces 8 Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor 9 Apply a light coating of pe...

Page 99: ...57 4 Rev A Reelmaster 2000 D Hydraulic System Page 4 This page is intentionally blank Hydraulic System ...

Page 100: ...eassembly C Allow hydraulic lines to drain into a suitable con tainer Put caps or plugs on disconnected hoses and fittings to prevent contamination D Remove two flange head screws that secure bot tom of hydraulic manifold to the mounting bracket E Support hydraulic manifold and remove flange head screw that secures hydraulic manifold to the cylinder support bracket Remove hydraulic man ifold from ...

Page 101: ...This page is intentionally blank Hydraulic System Reelmaster 2000 D Page 4 59 Hydraulic System ...

Page 102: ...te 29 Detent plate 30 Socket head screw 31 Orifice plug 32 Indicator plate 33 Nut Figure 46 32 1 2 3 4 6 5 8 7 10 9 17 19 18 20 21 22 23 24 25 26 27 28 29 30 12 11 13 15 3 4 10 33 3 4 14 11 12 3 4 22 21 4 3 16 26 27 29 30 25 24 31 PLUG TORQUE SAE 2 60 in lb 6 8 N m SAE 4 135 in lb 15 3 N m SAE 6 18 ft lb 24 4 N m SAE 8 45 ft lb 61 N m 35 ft lb 47 N m 35 ft lb 47 N m 35 ft lb 47 N m 35 ft lb 47 N m...

Page 103: ...r cleaning 8 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartri...

Page 104: ...e right in line with the indicator plate I On reel speed control valve turn knob counter clockwise until the arrow points at the number 5 Si multaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing at the number 1 on the locating plate 11 After reassembly if problems still exist remove valve and clean again or replace valve Hydraulic System Page 4 62 Reelmaster 200...

Page 105: ...This page is intentionally blank Hydraulic System Reelmaster 2000 D Page 4 63 Hydraulic System ...

Page 106: ... 27 N m 20 ft lb 27 N m 40 ft lb 54 N m 25 ft lb 34 N m 25 ft lb 34 N m 25 ft lb 34 N m 20 ft lb 27 N m 25 ft lb 34 N m 50 ft lb 67 N m 15 ft lb 20 N m NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port and SV is the location for the sole noid cartridge See Hydraulic Schematics to identify the function of the hydraulic lines ...

Page 107: ...moving mow backlap spool from mow manifold remove backlap switch dowel pin and ball 5 If necessary remove mow backlap spool from mow manifold A Remove backlap switch from mow manifold be fore removing mow backlap spool Remove dowel pin and ball from manifold port after switch is re moved Remove and discard O ring from switch B Remove lower retaining ring from mow backlap spool Raise mow backlap sp...

Page 108: ...ge valves Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate threads of cartridge valve with clean hydraulic oil Thread cartridge valve carefully into correct manifold port The valve should go in easily without binding C Torque cartridge valve using a deep well socket to values identified in Figur...

Page 109: ...63 4 Rev A Reelmaster 2000 D Hydraulic System Page 4 This page is intentionally blank Hydraulic System ...

Page 110: ...c tube 2 Reverse hydraulic tube 3 Lock nut 4 3WD selector valve 5 Hydraulic fitting 6 90o hydraulic fitting 7 Cap screw 8 Flat washer 9 Tube clamp 10 Cap screw 11 O ring 12 O ring 13 Hydraulic hose 14 Frame skirt Figure 47 10 8 5 12 11 3 12 5 11 6 12 11 4 9 8 7 9 8 3 2 1 13 14 FRONT RIGHT 10 8 ...

Page 111: ...ow hy draulic oil to drain from hoses and tubes into a suitable container 6 Disconnect electrical connector from solenoid valve on selector valve 7 Remove cap screws and flat washers that secure se lector valve to frame skirt 8 Remove selector valve from machine 9 Remove fittings and O rings from selector valve Discard O rings Installation Fig 47 1 Install hydraulic fittings and new O rings into s...

Page 112: ...elector Valve Service 1 Selector Valve manifold 2 Solenoid valve 3 Pilot operated directional valve 4 Solenoid coil 5 Nut 6 O ring Figure 48 2 3 1 4 5 35 to 40 ft lb 47 to 54 N m 4 to 6 ft lb 5 4 to 8 1 N m 6 6 Thread locking 35 to 40 ft lb 47 to 54 N m Compound ...

Page 113: ...mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning 7 Reinst...

Page 114: ...g 7 O ring 8 Lift cylinder 9 Cotter pin 10 Clevis pin 11 Flange head screw 12 Lift hub 13 Cotter pin 14 Clevis pin 15 Lift chain clevis 16 Cylinder guide pin 17 Cylinder support bracket 18 Flange bushing 19 Valve mount bracket Figure 49 1 6 2 6 3 9 7 16 6 4 13 14 17 11 18 18 19 10 5 8 12 INSTALL FLANGE BUSHINGS 18 FROM THE INSIDE FITTING SIDE 15 HYDRAULIC 13 14 15 ...

Page 115: ...ut from the frame 11 Remove flange bushings 18 from the cylinder sup port bracket 17 12 Remove lift hub from the lift cylinder shaft Installation Fig 49 1 Thread lift hub onto lift cylinder and tighten fully 2 Position lift cylinder inside the cylinder support bracket and valve mount bracket Make sure the ports of the lift cylinder face the hydraulic fitting side of the cyl inder support bracket 3...

Page 116: ...ove and discard dust seal 12 3 Rotate head 3 with a spanner wrench and remove retaining ring as shown in Figure 51 4 Grasp end of shaft extract shaft head and piston 8 by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in vise 9 Uni ring 10 Lock nut 11 Barrel 12 Dust seal 5 Mount shaft securely in a vise by cl...

Page 117: ...e head onto the shaft Install piston and locknut onto the shaft and tighten lock nut 3 Remove shaft from vise IMPORTANT Prevent damage when clamping the barrel into a vise clamp on the pivot end only Do not close vise enough to distort barrel 4 Mount barrel in a vise so that the shaft end tilts up slightly 5 Coat all internal lift cylinder parts with a light coat of hydraulic oil Slide piston shaf...

Page 118: ... hydraulic fitting 12 Hydraulic fitting 13 Rear lift cylinder 14 Flat washer 15 Clevis pin 16 Cap screw 17 Lock washer 18 Cap screw 19 Flat washer 20 Rear lift arm 21 Thrust washer 22 Cutting unit pivot shaft 23 Flat washer 24 Flange head screw 25 Cap screw 26 Spacer 27 Reinforcement plate 28 O ring 29 O ring 30 Grease fitting Figure 53 2 26 7 27 3 4 25 5 20 22 21 23 24 15 1 14 18 17 19 16 17 14 1...

Page 119: ...s 11 and 12 clear the exhaust system 7 Remove cotter pin 1 and flat washer 14 from cle vis pin 15 Support lift cylinder and slide clevis pin with second flat washer out of the lift arm Remove lift cylin der from machine 8 Remove hydraulic fittings 11 and 12 and O rings from the lift cylinder Installation Fig 53 1 Coat new O rings lightly with clean hydraulic oil Install hydraulic fittings with new...

Page 120: ...t clamp vise jaws against shaft surface Protect shaft surface before mounting in the vise 5 Mount shaft securely in a vise Remove locknut and piston from the shaft Slide head off the shaft 6 Remove and discard uni ring 4 and O ring 5 from the piston Remove and discard dust seal 12 backup washer 9 and O rings 7 and 8 from the head 15 Grease fitting NOTE If the clevis rod 14 is to be removed from th...

Page 121: ...r this adjustment 3 Coat shaft lightly with hydraulic oil Slide head onto the shaft being careful not to damage O ring and dust seal 4 Install piston onto the shaft being careful not to dam age O ring Install locknut onto the shaft and tighten 5 Remove shaft from vise IMPORTANT Prevent damage when clamping the barrel into a vise clamp on the pivot end only Do not close vise enough to distort barre...

Page 122: ...2 26 24 2 23 10 24 24 25 24 25 24 6 28 IN RETURN A B 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Remove side panels Lift hood to gain access to the control valve and relief valve ...

Page 123: ...nections Lift Relief Valve Removal Fig 55 NOTE This procedure may be used if only the lift relief valve needs removal from the unit 1 Disconnect hose connection 9 from hydraulic tee fitting 7 Allow hose to drain hydraulic oil into a suitable container 2 Disconnect tube 21 from hydraulic tee fitting 7 Al low fitting to drain into a suitable container 3 Remove lift relief valve body 27 and hydraulic...

Page 124: ...latness Signs of wear on one side of the spool may indicate damage Replace a worn or damaged spool if necessary 3 Inspect other components for wear or damage and replace damaged items as necessary Control Valve Reassembly Fig 56 1 Coat all new O rings with hydraulic oil Install new O rings into the bore of the valve body 2 Coat spool lightly with hydraulic oil Push and twist spool carefully into t...

Page 125: ...oir plug Figure 57 1 2 24 6 7 8 9 10 11 12 5 13 20 14 22 24 21 24 22 14 18 13 13 10 11 12 5 17 5 3 25 4 14 24 16 15 19 15 23 26 30 to 60 in lb 3 4 to 6 8 N m Thread locking Compound 30 to 60 in lb 3 4 to 6 8 N m Thread locking Compound FRONT RIGHT Inspecting Reservoir Parts Fig 57 1 Clean tank and filler screen with solvent 2 Inspect tank for leaks cracks or other damage 3 Replace hydraulic hoses ...

Page 126: ...reen 3 Loosen hose clamps and remove both hydraulic hoses from fittings on oil cooler Allow hoses to drain oil into a suitable container 4 Remove 90o hydraulic fittings from oil cooler assem bly Remove and discard o rings from connectors 5 Remove bulkhead nuts from oil cooler assembly 6 Pull oil cooler from screen bracket 7 If necessary remove hydraulic connectors from oil cooler Installation Fig ...

Page 127: ...TEM QUICK CHECKS 8 Standard Control Module 18 Battery Test Open Circuit Test 8 Traction Neutral Switch 19 Charging System Test 8 Seat Switch 20 Glow Plug System Test 8 Parking Brake Switch 21 Starting System Test 9 Cutting Unit Interlock Switch 22 Check Operation of Interlock Switches 9 Backlap Switch 22 ADJUSTMENTS 10 Fuses 23 Neutral Switch 10 Diode Assembly 24 Parking Brake Switch 10 SERVICE AN...

Page 128: ...cs and Electrical Harness and Connectors Drawings The electrical schematics and other electrical drawings for the Reelmaster 2000 D are located in Chapter 8 Electrical Diagrams Electrical System Page 5 2 Reelmaster 2000 D ...

Page 129: ...nds the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internalresistance ofa digitalme ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Toro Part Number 505 165 which forms a ligh...

Page 130: ...cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty Nothing happens when start attempt is made either seat switch OR parking brake must be engaged for successful start Reel engage switch is ON pulled out or is faulty Batte...

Page 131: ...system is malfunctioning see Chapter 3 Engine Engine and or fuel may be too cold Standard Control Module is faulty Engine cranks but should not with the traction pedal Traction neutral switch is out of adjustment or faulty out of the neutral position Traction neutral switch wiring is faulty Reelmaster 2000 D Page 5 5 Electrical System Electrical System ...

Page 132: ...at switch is faulty or out of adjustment Seat switch wiring is loose corroded or damaged Battery does not charge Wiring to the charging circuit components is loose corroded or damaged see Wiring Schematics Fusible link to the battery is faulty Alternator is faulty Battery is dead Engine kills during operation operator sitting on seat Operator is lifting off the seat seat switch not depressed Seat ...

Page 133: ... present in seat Cutting units are not lowered System fuse 10 amp is open Fuse block is faulty Seat switch is faulty or out of adjustment Wiring to mow backlap circuit components is loose corroded or damaged see Wiring Schematics Reel engage switch is faulty Cutting unit interlock switch is faulty Cutting unit solenoid valve or coil on hydraulic manifold is faulty Cutting units do not engage in Ba...

Page 134: ...l increase at different rates as the battery charges Voltage Measured Battery Charge Level 12 68 v or higher Fully charged 100 12 45 v 75 charged 12 24 v 50 charged 12 06 v 25 charged 11 89 v 0 charged Start the engine and run at 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery volt age Test results should be example At least 0 50 volt over initial battery voltage Ini...

Page 135: ...cable Crank the engine for at least 3 se conds and record the results Maximum starter system draw for the RM 2000 D is 140 Amps at 65o F 18o C If current draw is significantly higher than listed check for a shorted condition If current draw is significantly lower than listed check for high resistance Check Operation of Interlock Switches CAUTION Do not disconnect safety switches They are for the o...

Page 136: ...opens when the traction pedal is moved forward 1 inch 2 5 cm measured at the top of pedal 1 Traction pedal 2 Neutral switch 3 Traction arm Figure 3 2 1 3 Parking Brake Switch 1 Adjust parking brake switch so switch opens within two 2 clicks of parking brake lever movement 1 Parking brake lever 2 Brake switch Figure 4 2 1 ...

Page 137: ...TART B I S Ignition Switch The ignition key switch has three positions OFF ON and START The terminals are marked as shown The circuit wiring of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals The Sta...

Page 138: ... light and circuit wiring start the engine and ground the blue white wire attached to high temperature shutdown switch located on water pump housing see High Temperature Shut down Switch in this Chapter Warning light should illu minate and engine should stop running Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in the ON position prior to placing t...

Page 139: ... OF LIGHT 1A 1B 3 Indicator light should illuminate Figure 11 Reel Engage Switch The reel engage switch is mounted on the instrument panel and is pulled to engage the cutting reels The Re elmaster 2000 D uses only two of the six switch termi nals When the switch knob is pulled switch terminals 1 COM C and 4 should have continuity Fig 12 When the switch knob is pushed in switch terminals 1 COM C an...

Page 140: ...ufacturers Verify manufacturer name and part number before performing the resistance check on the relay coil 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting A For the Tyco Electronics relay VF7 41F11 S01 resistance should be approxi mately 72 ohms B For the Hella Electronics relay 87430B resist ance should be approximately 100 ohms 2 Connect multimeter ohms sett...

Page 141: ...re the Module Hi Temp input LED should be illumi nated High Temperature Shutdown Switch Test 1 Lower the coolant level in the engine and remove the high temperature shutdown switch Figure 14 2 1 1 Temperature switch 2 Water pump housing 2 Put the switch in a container of oil with a thermometer and slowly heat the oil Fig 15 CAUTION Handle the hot oil with extreme care to prevent personal injury or...

Page 142: ...mmediately 2 Disconnect the gray wire from the switch 3 Turn the ignition switch to ON The oil pressure lamp should not be illuminated 4 If the light is still on check the oil switch circuit wiring 5 Return ignition switch to OFF and connect the gray wire to the switch See the Briggs Stratton Daihatsu Engine Repair Manual for engine oil pressure testing procedures Engine Run Solenoid The engine ru...

Page 143: ...measured value of the component you are testing NOTE The solenoid does not have to be removed from the valve for testing 1 Make sure engine is off Unplug solenoid valve elec trical connector 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off 4 Measure resistance between the two coil connector term...

Page 144: ...rd intermittent fault data The Standard Control Module can be used to check op eration of machine switches by monitoring the LED of the module If a Module LED does not illuminate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring would be required Refer to the Traction Unit Operator s Manual for...

Page 145: ... units stop engine engage parking brake and remove key from the ignition switch 2 Disconnect the electrical connector to the neutral switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With the ignition switch in the OFF position slowly push the traction pedal in the forward and reverse direc tion while watching the multimeter Conti...

Page 146: ...itors the operation of the seat switch If the ignition switch is in the ON position Figure 22 and the seat is occupied the Module in seat input LED 1 Electrical connector 2 Standard seat switch should be illuminated 1 Seat Switch Test 1 Make sure the engine is off 2 Disconnect electrical connector from the seat switch 3 Check the continuity of the switch by connecting a multimeter ohms setting acr...

Page 147: ...in the ON position and the parking brake is not applied the Module brake off input LED should be illuminated Parking Brake Switch Test 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Disconnect parking brake switch from machine wir ing harness 3 Check the continuity of the switch by connecting a multimeter ohms settin...

Page 148: ...n ifold It is normally open and is closed when the backlap knob is turn clockwise to the backlap position The Standard Control Module monitors the operation of the backlap switch If the ignition switch is in the ON position and the backlap knob is turned to the backlap position the Module backlap input LED should be illumi nated Backlap Switch Test 1 Locate backlap switch on hydraulic manifold Dis...

Page 149: ...and red wire battery Fuse 2 option A Supplies power to optional lights B Has blue wire and red wire C DO NOT use fuse greater than 15 amp Fuse 3 10 Amp A Supplies power from ignition switch terminal S B Has violet wire and tan wire Fuse 4 10 Amp A Supplies power from ignition switch terminal I B Has pink wire and yellow wire Testing Remove fuses from the fuse block for testing Fuse should have con...

Page 150: ... Harness Drawings in Chapter 8 Electrical Diagrams Diode Test The diode Fig 28 can be tested using a digital multime ter diode test or ohms setting and the table below 3 1 Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal Female Male YES Male Female NO Figure 28 1 Diode 3 Female terminal 2 Male terminal Electrical System Page 5 24 Reelmaster 2000 D ...

Page 151: ...ult if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery fill caps while cleaning 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case ...

Page 152: ... is 0 1 amp or more the unit s electrical sys tem should be tested and repaired Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts 2 1 Figure 29 1 Negative battery cable 2 Positive battery cable IMPORTANT Before cleaning ...

Page 153: ... a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor G Take a voltage reading at 15 ...

Page 154: ... battery electrolyte If the temperature exceeds 125oF 51 6oC or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 chang...

Page 155: ...that o ring is installed at each end of coil Align the coil assembly evenly with the manifold body 2 Apply medium strength thread locking compound to the threads of the spool Install the nut onto the spool as sembly and torque as follows do not over tighten A Torque nut for reel drive solenoid from 2 to 5 ft lb 2 7 to 6 8 N m B Torque nut for 3WD solenoid from 4 to 6 ft lb 5 to 8 N m 3 Connect the...

Page 156: ...This page is intentionally blank Electrical System Page 5 30 Reelmaster 2000 D ...

Page 157: ...Standard Seat 10 SERVICE AND REPAIRS 4 Suspension Seat 11 Rear Wheel Standard 2 Wheel Drive 4 Steering Assembly 12 Rear Wheel Optional 3 Wheel Drive 6 Front Lift Arms 14 Front Wheels and Brakes 8 Rear Lift Arm 15 Reelmaster 2000 D Page 6 1 Chassis Chassis ...

Page 158: ... ply tubeless Rear tire pressure 16 to 20 PSI 1 1 to 1 38 bar 20 x 8 8 4 ply tube type Front and rear wheel lug nut torque 45 to 65 ft lb 61 to 88 N m Front hub nut torque 250 to 400 ft lb 339 to 542 N m 3WD rear hub nut torque 250 to 400 ft lb 339 to 542 N m Chassis Page 6 2 Reelmaster 2000 D ...

Page 159: ...This page is intentionally blank Reelmaster 2000 D Page 6 3 Chassis Chassis ...

Page 160: ...Lock nut 13 Cotter pin 14 Rear wheel fork 15 Hub 16 Socket head screw 17 Jam nut 18 Grease fitting 19 Lock washer 20 Thrust washer 21 Cap screw 22 Ball joint 23 Jam nut left hand thread 24 Jam nut 25 Ball joint 26 Steering tube Figure 1 9 1 15 12 14 16 17 26 23 22 19 20 21 18 6 5 4 13 2 10 3 11 7 7 8 25 24 FRONT RIGHT 60 to 80 ft lb 81 to 108 N m 45 to 65 ft lb 61 to 88 N m 15 to 20 ft lb 20 to 27...

Page 161: ...Inspect bearing cups in wheel hub for wear or dam age If bearing cups are damaged replace the wheel hub Installation Fig 1 1 If seal and inner bearing were removed from the wheel hub place greased bearing cone into inner bear ing cup Install new seal 2 Slide wheel hub onto machine Position greased out er bearing and tab washer onto shaft 3 Install jam nut onto shaft and tighten Back off jam nut an...

Page 162: ...eel Optional 3 Wheel Drive 1 Rear wheel fork 2 Steering tube assembly 3 Rear wheel motor 4 Key 5 Drive stud 6 Wheel hub 7 Wheel assembly 8 Lock nut 9 Lug nut Figure 2 6 5 3 8 7 9 4 1 2 250 to 400 ft lb 339 to 542 N m 45 to 65 ft lb 61 to 88 N m ...

Page 163: ...amage to the wheel motor 5 Use a puller to remove the wheel hub Remove the key from the wheel motor shaft 6 Remove rust from all parts with a wire brush prior to installation Clean all parts Replace any worn or dam aged components Installation Fig 2 1 Install key and wheel hub onto the wheel motor shaft 2 Install lock nut to wheel motor shaft and tighten to a torque of 250 to 400 ft lb 339 to 542 ...

Page 164: ...21 28 6 8 7 10 9 16 12 11 13 14 15 18 27 FRONT RIGHT 33 30 32 32 31 31 29 250 to 400 ft lb 339 to 542 N m 45 to 65 ft lb 61 to 88 N m Anti seize lubricant 34 Removal 1 Park machine on a level surface lower cutting units stop engine and remove key from the ignition switch 2 Make sure brake is disengaged 3 Lift front wheel off the ground using a jack Block front and rear of other wheels 4 Remove lug...

Page 165: ... 29 to the brake bracket with the cap screws 9 and lock nuts 6 Tighten fasteners 3 Connect brake lever 22 to the yoke 23 Install yoke pin 21 through the brake lever and yoke Install and lock cotter pin 28 into the yoke pin Fig 4 4 Install brake shoes 32 onto the backing plate 29 Install brake return springs 31 into the holes on each end of the brake shoes Springs should be installed in opposite di...

Page 166: ... guide 2 Position seat to the machine frame 3 Connect electrical connector to the seat switch 4 Secure seat to the frame with four cap screws and lock nuts 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove four cap screws and lock nuts securing the seat to the machine frame 3 Disconnect electrical connector from ...

Page 167: ...Shock absorber 39 Nut 40 Washer 41 Bushing kit incl 39 40 42 Backrest plate 43 Hex flange nut 44 Cap screw Figure 6 31 32 33 34 35 36 37 38 39 4041 42 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 5 43 44 Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove four cap screws ...

Page 168: ...ap screw 12 Grease fitting 13 Sector gear 14 Jam nut 15 Thrust washer 16 Flange bushing 17 Flat washer 18 Lock nut 19 Cap screw 20 Thrust washer 21 Lock washer 22 Flange bushing 23 Rear wheel fork 24 Jam nut LH thread 25 Ball joint 26 Steering tube 27 Jam nut 28 Ball joint Figure 7 1 2 3 4 5 6 7 6 10 8 9 9 12 11 12 18 17 16 16 15 14 13 22 22 23 21 20 19 FRONT RIGHT 28 27 26 24 25 14 60 to 80 ft lb...

Page 169: ...rs as needed to align gear tops Gears should not contact flange bushings B Adjust steering tube ball joints equally so that steering sector gear and rear wheel fork are perpen dicular to the frame C If rear wheel fork was removed secure fork to frame with washers and cap screw Torque cap screw from 60 to 80 ft lb 81 to 108 N m Make sure that fork rotates freely after cap screw has been tight ened ...

Page 170: ...t arm pivot shaft 24 Spring tension arm 25 Spacer 26 Cap screw 27 Self tapping screw 28 Cap screw 29 Chain Figure 8 13 12 10 10 11 17 13 15 18 10 12 14 16 2 3 1 9 4 5 6 8 9 7 24 26 23 22 27 28 20 29 19 21 20 20 25 19 FRONT RIGHT Disassembly 1 Remove cutting unit from lift arm see Traction Unit Operator s Manual 2 Remove front lift arm components from machine us ing Figure 8 as a guide Assembly 1 I...

Page 171: ... arm 19 Lock nut 20 Clevis pin 21 Shackle 22 Cotter pin 23 Sleeve 24 Spring Figure 9 18 17 12 16 15 14 13 8 9 10 11 4 5 6 7 20 3 2 19 2 1 21 23 24 22 5 FRONT RIGHT Disassembly 1 Remove cutting unit from lift arm see Traction Unit Operator s Manual 2 Remove rear lift arm components from machine us ing Figure 9 as a guide Assembly 1 Install rear lift arm components to machine using Fig ure 9 as a gu...

Page 172: ...This page is intentionally blank Chassis Page 6 16 Reelmaster 2000 D ...

Page 173: ...ut 6 ADJUSTMENTS 8 Characteristics 8 SERVICE AND REPAIRS 9 Hydraulic Reel Motor 9 Bedbar 10 Bedknife Replacement and Grinding 12 Front and Rear Rollers 13 Roller Service 14 Cutting Reel 16 Prepare Reel for Grinding 18 Fixed Side Plate Installation 19 Skid Kit Installation 20 Reelmaster 2000 D Page 7 1 Cutting Units Cutting Units ...

Page 174: ...knob screw adjustment for bedknife to reel is located at the center of the bedbar CUTTING UNIT LIFT Hydraulic lift has an automatic reel shut off Lift for all cutting units are controlled from one lever SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance L I N K STM cutting unit suspension system provides fore and aft oscillation Main center pivot allows side to side oscill...

Page 175: ...This page is intentionally blank Reelmaster 2000 D Page 7 3 Cutting Units Cutting Units ...

Page 176: ...i tude Toro Part Number 98 1852 Figure 2 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Toro Part Number TOR299100 Figure 3 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT Do not use an air or manua...

Page 177: ... grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator Toro part no 97931SL Toro Model Number 04399 Figure 6 Reelmaster 2000 D Page...

Page 178: ...eel speed and ground speed Adjust reel speed to setting shown on REEL SPEED SELECTION CHART for the number of reel blades 5 or 8 and the desired ground speed see Traction Unit Operator s Manual All reels should rotate at the same speed All cutting units should have equal bedknife to reel contact If checking RPM do not run reel too long without cutting grass or bedknife and or reel may overheat and...

Page 179: ...ing height of cut 9 Height of cut Make sure all cutting units are set at the same height of cut Set units as specified in the Cutting Unit Operator s Manual 10 Bedbar stability Check bedbar end bushings adjuster pivot bushings and nylon flanged bushings for wear or damage Check bedbar adjustment knob to make sure detent holds adjustment 11 Number of reel blades Use cutting unit model with the corr...

Page 180: ...de a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlap ping In addition the rear roller positioning system permits op timum bedknife attitude and location for varying height of cuts and turf conditions If a cutting unit is determined to be out of adjustment complete the following procedures in th...

Page 181: ...ads Replace coupler if threads are worn Reinstall reel cou pler see Cutting Reel Installation Fig 7 NOTE The cutting unit can be installed with the hy draulic motor on either side If installing on the opposite side remove cap screws cover and cover gasket rein stall them on the other bearing housing 1 Dip spider coupler in No 2 general purpose lithium base grease Reinstall spider coupler into the ...

Page 182: ... lb 28 to 34 N m 30 31 32 PERMANENT THREAD LOCKING COMPOUND Removal 1 Turn bedbar adjuster to loosen bedknife to reel con tact Unscrew bedbar adjuster left hand threaded while loosening jam nut from the compression spring until the bedbar fitting is clear of the bedbar yoke 2 Remove capscrew lock washer flat washer and spacer from the right end of the bedbar 3 Loosen adjustment nuts on the adjusti...

Page 183: ...th carriage bolts and nuts 6 Secure adjusting housing to the cutting unit with both carriage bolts and nuts Fig 9 7 Tighten both adjusting nuts on the adjusting housing Fig 9 8 Position bedbar fitting to the bedbar yoke Screw ad justing handle left hand threaded until the bedbar fit ting is snug against the bedbar yoke 9 If weights were removed from bedbar Models 03213 and 03214 apply permanent th...

Page 184: ...perfectly flat after it is installed It is therefore necessary to back lap or grind a new bedknife after installing it to the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface is true 6 Install bedbar to the cutting unit see Bedbar Installa tion Regrinding Bedknife Remove bedbar assembly from cutting unit before at tempting to re...

Page 185: ...ht of cut brackets mate with the hex adjust ment nut on the roller 3 Hold one height of cut bracket stationary and use the other bracket as a wrench to loosen or tighten bear ing clearance The roller must not exceed 5 in lb 0 57 N m rolling torque and have no bearing end play 4 Make sure height of cut brackets are aligned prior to installing them onto the cutting unit If necessary after bearing ad...

Page 186: ...al roller remove adjustment nuts from each end of the roller 3 Keep roller level and slide the shaft with the remain ing adjustment nut out of the roller On the sectional roll er slide both sectional rollers off the shaft 4 Secure roller in a vise 5 Remove outer seals 6 Remove both bearing cones On the sectional roller remove all four bearing cones NOTE An electric arc welder can be used to shrink...

Page 187: ...earing end play and rolling torque does not ex ceed 5 in lb 0 57 N m 11 Grease bearings see Cutting Unit Operator s Manu al Sectional Roller Assembly 1 Make sure all parts are clean prior to installing bear ings and seals 2 Press two bearing cups into each sectional roller Make sure narrow end of taper faces the inside of the roller 3 Secure sectional roller shaft in a vise Make sure shaft is leve...

Page 188: ...OMPOUND THREAD LOCKING COMPOUND ANTI SEIZE LUBRICANT 36 36 Remove Cutting Reel Fig 14 1 Remove hydraulic motor from the cutting unit see Hydraulic Reel Motor Removal Remove cover and gasket from the opposite end of the cutting unit 2 Remove cutting unit from the machine see Traction Unit Operator s Manual 3 Remove bedbar assembly from the cutting unit see Bedbar Removal 4 Remove front roller from ...

Page 189: ... of the housing 5 Slide bearings and bearing housings onto the reel shaft 6 Make sure bearing housings are installed with the grease fittings pointing up and to the front of the cutting unit 7 Secure bearing housings to the cutting unit with flange head screws 8 Remove any grease from the threaded end of the reel couplers and the reel shaft Make sure grease is completely removed 9 Apply medium str...

Page 190: ...sired cylinder shape NOTE When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 After completing grinding process A Install front roller and brackets see Roller Re moval and Installation B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s...

Page 191: ...ig 17 4 Attach fixed side plate to the cutting unit with cap screws washers and flanged lock nuts Fig 17 5 Tighten lock nuts and cap screws 6 Fasten new height of cut plate to the cutting unit with pop rivets Fig 17 7 Repeat steps 1 through 6 on the other side of the cut ting unit 1 Pop rivet 2 Height of cut plate 3 Lock nut 4 Cap screw 5 Washer 6 Link 4 6 1 2 5 3 Figure 16 1 Fixed side plate 2 Ca...

Page 192: ... with both flange head screws flat washers and lock nuts 4 Repeat steps 1 through 3 on the other side of the cut ting unit 5 Adjust skid height as necessary by loosening lock nuts and flange head screws After skid height adjust ment retighten fasteners 3 1 4 5 2 Figure 18 1 Skid 4 Flat washer 2 Angle bracket holes 5 Lock nut 3 Flange head screw Cutting Units Page 7 20 Reelmaster 2000 D ...

Page 193: ...3 Serial Number Above 230000000 4 CIRCUIT DIAGRAMS 5 Glow Plug Circuit Diagram 5 Crank Circuit Diagram 6 Run Transport Circuit Diagram 7 Run Mow Circuit Diagram 8 WIRE HARNESS DRAWINGS 10 Main Wire Harness Drawing Serial Number Below 230000000 10 Main Wire Harness Drawing Serial Number Above 230000000 12 Engine Wire Harness Drawing 14 Electrical Diagrams ...

Page 194: ...This page is intentionally blank Electrical Diagrams Page 8 2 Reelmaster 2000 D ...

Page 195: ...8 3 Electrical Schematic Reelmaster 2000 D All relays and solenoids are shown as de energized All ground wires are black IF EQUIPPED SOLENOID 3 WD IN OFF IN NEUTRAL UNOCCUPIED IN OFF Serial Number Below 230000000 ...

Page 196: ...Rev A Page 8 4 Electrical Schematic Reelmaster 2000 D All relays and solenoids are shown as de energized All ground wires are black Serial Number Above 230000000 ...

Page 197: ...ge 8 5 Glow Plug Circuit Power Current Control Current Indicator Gauge Current Logic Direction Reelmaster 2000 D IF EQUIPPED SOLENOID 3 WD IN NEUTRAL IN OFF IN OFF UNOCCUPIED Serial Number Below 230000000 Shown ...

Page 198: ...N OFF IN NEUTRAL UNOCCUPIED NOTE The engine will crank with either the parking brake engaged or the seat occupied Crank Circuit Power Current Control Current Indicator Gauge Current Logic Direction Reelmaster 2000 D Serial Number Below 230000000 Shown ...

Page 199: ... EQUIPPED SOLENOID 3 WD OCCUPIED IN OFF NOT IN NEUTRAL IN OFF DISENGAGED Run Transport Circuit Power Current Control Current Indicator Gauge Current Logic Direction Reelmaster 2000 D Serial Number Below 230000000 Shown ...

Page 200: ...UIPPED SOLENOID 3 WD OCCUPIED IN OFF NOT IN NEUTRAL IN ON DISENGAGED REELS LOWERED Run Mow Circuit Power Current Control Current Indicator Gauge Current Logic Direction Reelmaster 2000 D Serial Number Below 230000000 Shown ...

Page 201: ...Rev A Page 8 9 This page is intentionally blank ...

Page 202: ...BROWN WHITE BLUE WHITE GREEN ORANGE BLACK TAN BLACK TAN VIOLET VIOLET BROWN BLACK PINK BLUE WHITE WHITE PINK PINK WHITE PINK PINK WHITE BLACK YELLOW PINK TAN BLUE ORANGE PINK BLACK RED GREEN PINK GRAY BLACK BLACK RED YELLOW PINK PINK PINK RED BROWN RED BLACK GRAY BLUE WHITE Serial Number Below 230000000 ...

Page 203: ...Rev A Page 8 11 Reelmaster 2000 D Main Wire Harness Serial Number Below 230000000 ...

Page 204: ...IOLET BROWN BLACK BLUE WHITE PINK WHITE PINK WHITE BLACK YELLOW PINK TAN BLUE ORANGE PINK PINK PINK ORANGE VIOLET ORANGE PINK ORANGE RED PINK PINK RED PINK BLACK PINK BLUE WHITE BLACK BLACK BLACK BLACK BLACK BLACK YELLOW GRAY BLUE WHITE GRAY BLACK Reelmaster 2000 D Main Wire Harness Serial Number Above 230000000 ...

Page 205: ...Rev A Page 8 13 Reelmaster 2000 D Main Wire Harness Serial Number Above 230000000 ...

Page 206: ...Rev A Page 8 14 Reelmaster 2000 D Engine Wire Harness RED PINK YELLOW BLACK WHITE RED BLACK GRAY BLUE WHITE WHITE BLACK GREEN ORANGE BLACK BROWN GREEN GREEN GREEN BLACK BLACK ...

Page 207: ...Rev A Page 8 15 Reelmaster 2000 D Engine Wire Harness ...

Page 208: ...Rev A Page 8 16 This page is intentionally blank ...

Search results

Summary of Contents for Reelmaster 2000-D

Reviews:

Related manuals for Reelmaster 2000-D

Brands by name

Popular brands

Toro Reelmaster 2000-D, Service Manual

Search results

Summary of Contents for Reelmaster 2000-D

Reviews:

Related manuals for Reelmaster 2000-D

Brands by name

Popular brands